Product Package

ABSTRACT

A product package formed from a vertical form, fill, seal process includes a single piece of film arranged and configured to define a container portion. The container includes a top seal portion, a bottom seal portion, and one side seal portion. Additionally, the container includes at least one folded side edge. The top and bottom seal portions include concave edges defining convex profiles of the container portion. The convex profiles of the container portion intersect the side seals to advantageously blunt corners of the product package to advantageously reduce localized stresses.

FIELD OF THE INVENTION

The present invention generally relates to product packages and, moreparticularly, to product packages constructed from plastic film.

BACKGROUND

Various small, granulated, or fluidic products are often sold ordistributed in individual plastic packages resembling pouches, forexample. Some such packages include transparent film such that consumersmay readily identify the contents. Others may include labeling or otherindicia for identifying the contents. Such plastic packages areconventionally formed and filled in an automated process. Oneconventional automated process includes a vertical form, fill, and seal(VFFS) process.

FIG. 1 depicts a conventional package 10 produced from a conventionalVFFS process. The package 10 is constructed from a single piece oftransparent plastic film, for example, and includes a container portion12, a top seal 14, a bottom seal 16, and a side seal 18. The containerportion 12 includes first and second side edges 12 a, 12 b, a top edge12 c, and a bottom edge 12 d. The first side edge 12 a results from afold in the plastic film.

One conventional VFFS process for producing the package 10 depicted inFIG. 1, for example, includes an apparatus such as an assembly machinethat wraps a single piece of the plastic film around a verticallyoriented feed tube. The machine heat seals or otherwise secures theopposing edges of the film together to create the side seal 18 and forma hollow tube of film. Subsequently, the machine heat seals or otherwisecreates the bottom seal 16, which is disposed transverse to thelongitudinal direction of the tube of film, thereby defining thecontainer portion 12 with an open top where the top seal 14 will laterbe formed. The open top end, at this point, is disposed adjacent to anoutlet of the feed tube. Thereafter, the machine introduces a specifiedamount of flowable product into the container portion 12 via the feedtube. Once the container portion 12 includes the desired amount ofproduct, the machine advances the film to another heat sealing device,for example, to create the top seal 14. Finally, the machine advancesthe film to a cutter that cuts the film immediately above the top seal14 to provide the filled package 10.

As illustrated in FIG. 1, the conventional package is generallyrectangular in shape. Specifically, the top and bottom seals 14, 16, aswell as the top and bottom edges 12 c, 12 d of the container portion 12,are generally linear and disposed substantially perpendicular to theside seal 18. The side edges 12 a, 12 b of the container portion 12,however, are slightly curved, or concave. This curvature is due to thecontainer portion 12 containing product, and therefore expanding in adirection perpendicular to the side edges 12 a, 12 b, which draws theside edges 12 a, 12 b inward.

The conventional package 10 may be offered for distribution as a singleunit (as shown in FIG. 1), or with a plurality of other similar packagesin a bag or a box. Still further, a plurality of packages 10 may beoffered for sale in a blister pack, where each blister stores a singlepackage 10 containing product. Blister-packs may be beneficial forstoring the packages 10 when the packages are constructed of awater-soluble film, for example. When being offered for sale ordistribution, space may be limited for the storage of the package 10.Therefore, the top and bottom seals 14 and 16 may be folded over such asdepicted in FIG. 2. The folded-over configuration of the package 10 maybe especially beneficial for storing the packages in blisters of ablister-pack, which may have size constraints.

Whether the top and/or bottom seals 14, 16 are folded over or not, theconventional package 10 includes pointed corners 20 where the first andsecond side edges 12 a, 12 b meet the top and bottom edges 12 c, 12 d.In the conventional package 10 depicted in FIGS. 1 and 2, the first andsecond side edges 12 a, 12 b intersect the top and bottom edges 12 c, 12d at angles β that are equal to or less than approximatelyninety-degrees (90°).

One shortcoming of this conventional package 10 includes theconcentration of stresses at the pointed corners 20 due to pressuresgenerated within the container portion 12 of the package 10, especiallywhen the package 10 stores a fluid product. Another shortcoming of theconventional package 10 is that the pointed corners 20 disposed alongthe first side edge 12 a of the container portion 12 are constantlyexposed in a manner that increases their susceptibility to scrapingagainst surfaces such as storage bins, counter tops, pocket liners, etc.Such scraping may cause the pointed corners 20 to tear, thereby leakingthe contents of the container portion 12.

SUMMARY

One embodiment of the present invention includes a product packageconstructed from a single sheet of film. The single sheet of film isarranged and configured to comprise a container portion. The containerportion includes a side edge and opposing end edges. The end edges aredisposed transverse to the side edge. At least one of the end edges ofthe container portion comprises a convex profile.

Another embodiment of the present invention includes a method of forminga package from a single sheet of film. The method comprises wrapping thesingle sheet of film about a longitudinal axis of the film. Then,opposing sidewalls of the wrapped film are sealed together along a firstpath that is transverse to the longitudinal axis to form a first endseal portion. The first end seal portion comprises an edge having aconcave profile. Then, the opposing sidewalls of the wrapped film arescaled together along a second path that is transverse to thelongitudinal axis of the film to form a second end seal portion. Thesecond end seal portion is longitudinally spaced from the first end sealportion. The first and second end seal portions at least partly define acontainer portion that is adapted to contain a substance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a conventional package constructed by aconventional vertical form, fill, seal process;

FIG. 2 is a front view of the conventional package of FIG. 1 configuredwith its top and bottom seals folded;

FIG. 3 is a front view of a first embodiment of a package constructed inaccordance with the principles of the present invention;

FIG. 4 is a front view of the package of FIG. 3 configured with its topand bottom seals folded;

FIG. 5 is a front view of an alternative embodiment of a packageconstructed in accordance with the principles of the present invention;

FIG. 6 is a perspective schematic view of one embodiment of a verticalform, fill, seal machine for producing the package of FIGS. 3 and 4 inaccordance with the principles of the present invention;

FIG. 7 is a partial schematic view of one embodiment of a vertical form,fill, seal machine for producing the package of FIG. 5 in accordancewith the principles of the present invention, and taken from circle VIIfrom FIG. 6;

FIG. 8 is a front view of another alternative embodiment of a packageconstructed in accordance with the principles of the present invention;and

FIG. 9 is a front view of yet another alternative embodiment of apackage constructed in accordance with the principles of the presentinvention.

DETAILED DESCRIPTION

FIG. 3 depicts one embodiment of a product package 100 constructed inaccordance with the principles of the present invention. The package 100is constructed from a single piece of transparent plastic film such as anon-water-soluble film, a water-soluble film, or an edible water-solublefilm, for example. In general, the single piece of film includesopposing film portions 102 a, 102 b folded to define a first side edge110 a of the package 100. The package 100 includes a container portion102, a top seal portion 104, a bottom seal portion 106, and a side sealportion 108. The container portion 102 defines an internal cavity, orcontainment cavity defined between the opposing folded over filmportions 102 a, 102 b. The container portion 102 is therefore adapted toaccommodate a substance (not shown) such as fluid, granulated matterscandy, etc. For the sake of description, the container portion 102includes the first side edge 110 a, a second side edge 110 b, a top edge110 c, and a bottom edge 110 d. As mentioned, the first side edge 110 aincludes a folded edge of the plastic film and, in one embodiment, canbe creased. The second side edge 110 b abuts the side seal portion 108.In the disclosed embodiment, the top edge 110 c includes a convexprofile and abuts the top seal portion 104. Similarly, the bottom edge110 d of the disclosed embodiment includes a convex profile and abutsthe bottom seal portion 106. The top and bottom edges 110 c, 110 dintersect the first and second side edges 110 a, 110 b at corners 112having angles α that are greater than ninety-degrees (90°) due to theconvex curvature of the top and bottom edges 110 c, 110 d. In thedisclosed embodiment, the top and bottom edges 110 c, 110 d mayintersect the side edges 110 a, 111 b at angles α of approximatelyone-hundred and thirty-five degrees (135°), for example. Accordingly,the corners 112 also include angular dimensions a of approximately onehundred and thirty-five degrees (135°). However, in alternativeembodiments, the top and bottom edges 110 c, 110 d may intersect theside edges 110 a, 110 b at generally any angle α greater thanninety-degrees (90°) depending on the radius of convex curvature, orother configuration, of the top and bottom edges 110 c, 110 d.

As mentioned, the package 100 further includes the top seal portion 104,the bottom seal portion 106, and the side seal portion 108. In thedisclosed embodiment, the top, bottom, and side seal portions 104, 106,108 include portions of the folded, opposing film portions 102 a, 102 badhered together by heat sealing, for example, or some other fashion.

For the purposes of description, the top seal portion 104 includes amating edge 104 a and a free edge 104 b. The mating edge 104 a islocated proximal to the container portion 102. The free edge 104 b isspaced from the mating edge 104 a and located distal to the containerportion 102. The mating edge 104 a includes a concave profile abuttingthe convex top edge 110 c of the container portion 102. The free edge104 b includes a linear profile and is disposed substantiallyperpendicular to the side edges 110 a, 110 b of the container portion102.

Similarly, the bottom seal portion 106 includes a mating edge 106 a anda free edge 106 b. The mating edge 106 a is located proximal to thecontainer portion 102. The free edge 106 b is spaced from the matingedge 106 a and located distal to the container portion 102. The matingedge 106 a includes a concave profile abutting the convex bottom edge110 d of the container portion 102. The free edge 106 b includes alinear profile and is disposed substantially perpendicular to the sideedge 110 b of the container portion 102.

Finally, the side seal portion 108 also includes a mating edge 108 a anda free edge 108 b. The mating edge 108 a is located proximal to thecontainer portion 102. The free edge 108 b is located distal to thecontainer portion 102. The mating edge 108 a includes a linear profiledefined by the second side edge 110 b of the container portion 102. Thefree edge 108 b includes a linear profile spaced from the mating edge108 a and disposed substantially parallel to the second side edge 110 bof the container portion 102.

Thus, the container portion 102 of the package 100 depicted in FIG. 3includes a generally rectangular profile having convex-shaped top andbottom edges 110 c, 110 d. Similarly, the entire package 100 includes agenerally rectangular profile. The rectangular profile of the package100 is defined by the free edges 104 b, 106 b, 108 b of the sealportions 104, 106, 108 and the first side edge 110 a of the containerportion 102.

Although depicted and described as generally linear, the first andsecond side edges 110 a, 110 b of the container portion 102 mayalternatively include slightly curved concave profiles. Such curvaturemay be the result of the container portion 102 containing a substance orother product. Specifically, the substance may expand the containerportion 102 in a direction perpendicular to the side edges 110 a, 110 b,thereby drawing the side edges 110 a, 110 b inward.

Similar to the conventional package 10 discussed above with reference toFIGS. 1 and 2, the package 100 may be distributed as a single unit (asshown in FIG. 3), or with a plurality of other similar packages in a bagor a box, for example. Still further, a plurality of packages 100 may bedistributed or offered for sale in a blister-pack, wherein each blisterstores a single package 100 containing product. Blister-packs may bebeneficial for storing the packages 100 when the packages areconstructed of a water-soluble film or an edible water-soluble film.Additionally, when offered for sale or distribution, space may belimited for the storage of the package 100. Therefore, the top andbottom seal portions 104 and 106 may be folded over such as depicted inFIG. 4. The folded-over configuration of the package 100 may beespecially beneficial for storing the packages in blisters of ablister-pack, which may have size constraints or contoured sidewalls.Additionally, the folded over configuration can protect the corners 112of the package 100, as described below.

FIG. 5 depicts an alternative embodiment of a product package 200constructed in accordance with the principles of the present invention.The product package 200 is generally similar to the package 100 depictedin FIGS. 3 and 4.

Specifically, the package 200 includes a container portion 202, a topseal portion 204, a bottom seal portion 206, and a side seal portion208. Identical to the container portion 102 of the package 100 describedabove with reference to FIGS. 3 and 4, the container portion 202 of thepackage 200 in FIG. 5 includes generally linear first and second sideedges 210 a, 210 b and convex top and bottom edges 210 c, 210 d.Therefore, the convex top and bottom edges 210 c, 210 d intersect theside edges 210 a, 210 b at angles α that are greater than ninety-degrees(90). At least in one embodiment, the convex top and bottom edges 210 c,210 d may intersect the side edges 210 a, 210 b at angles α ofapproximately one-hundred and thirty-five degrees (135°). Accordingly,the container portion 202 also includes corners 212 having angulardimensions a of approximately one-hundred and thirty-five degrees(135°).

Moreover, the top and bottom seal portions 204, 206 include respectivemating edges 204 a, 206 a and free edges 204 b, 206 b. Identical to thepackage 100 discussed above with reference to FIGS. 3 and 4, the matingedges 204 a, 206 a of the package 200 depicted in FIG. 5 include concaveprofiles defined by the convex top and bottom edges 210 c, 210 d of thecontainer portion 202. In contrast to the previous embodiment of thepackage 100, however, the free edges 204 b, 206 b of the top and bottomseal portions 204, 206 of the package 200 depicted in FIG. 5 alsoinclude convex profiles. In the embodiment disclosed in FIG. 5, theconvex free edges 204 b, 206 b of the top and bottom seal portions 204,206 are disposed concentric with the convex top and bottom edges 210 c,210 d of the container portion 202, respectively. In alternativeembodiments, however, the convex free edges 204 b, 206 b of the top andbottom seal portions 204, 206 may not be disposed concentric with theconvex top and bottom edges 210 c, 210 d of the container portion 202.Furthermore, this alternative embodiment of the package 200 may bedistributed to consumers, for example, as a single unit (as shown inFIG. 5), as a plurality of units in a bag or a box, or in blister-packs.Thus, as discussed above, it may be beneficial to fold the top andbottom seal portions 204, 206 to conserve space in a manner similar tothat disclosed with reference to the package 100 depicted in FIG. 4.

As mentioned above, the various embodiments of the packages 100, 200 ofthe present invention may be constructed with a single piece oftransparent film such as a non-water-soluble film, a water-soluble film,or an edible water-soluble film, for example. The packages 100, 200 mayalso be constructed of other films and materials, whether transparent,or not. Construction of the packages 100, 200 may be achieved throughvarious methods. One method that may be utilized to construct thepackages 100, 200 includes a vertical form, fill, seal (VFFS) process.

FIG. 6 schematically illustrates a portion of a VFFS machine 300 forperforming a process and constructing a plurality of packages 100 inaccordance with the present invention. The machine 300 depicted in FIG.6 is specifically designed to form a plurality of the packages 100depicted in FIGS. 3 and 4. The machine 300, however, may be adapted toform a plurality of the packages 200 depicted in FIG. 5, as will bedescribed below.

FIG. 6 illustrates the machine 300 as generally including a feed tube302, a longitudinal sealer 304, a transverse sealer 306, and a cutter308. In the disclosed embodiment, the longitudinal sealer is disposedadjacent the feed tube 302; the transverse sealer 306 is disposeddownstream from the longitudinal sealer 304; and the cutter 308 isdisposed downstream from the transverse sealer 306. The machine 300 isadapted to form a plurality of packages 100 from a single piece of film310, which may be supplied from a single roll of film (not shown). Thefilm 310 preferably comprises an elongated film having a longitudinalaxis. The feed tube 302 includes an elongated hollow cylindrical tubeoriented generally vertically. The feed tube 302 includes a top end 302a and a bottom end 302 b. The top end 302 a is in communication with aproduct source (not shown) such as a hopper containing a substance orproduct to be delivered to the package 100 and combined therein. Thebottom end 302 b is disposed within the package 100 during anintermediate forming stage, as will be described. The longitudinal andtransverse sealers 304, 306 each include, at least in one embodiment, aheat sealer. The longitudinal sealer 304 includes a pair of identicalrectangular sealing irons 304 a for being compressed together, only oneof which is illustrated in FIG. 6. The longitudinal sealer 304 is thusarranged to create the side seal portion 108 on the packages 100. Thetransverse sealer 306 also includes a pair of identical sealing irons306 a for being compressed together, only one of which is illustrated inFIG. 6. The sealing irons 306 a of the transverse sealer 306 includeopposing top and bottom concave edges 307 a, 307 b for forming acombination seal 107, as will be described. The cutter 308 includes apair of cutting members 308 a, only one of which is depicted in FIG. 6.At least one of the cutting members 308 a includes a linear cuttingblade 308 b, which is shown in phantom, for cutting the film 310. Inalternative embodiments, however, the cutter 308 can include a hot wire,or some other device capable of cutting the film 310 as desired.

During operation, the machine 300 initially advances the film 310 fromthe roll and wraps, or otherwise folds, the film 310 about itslongitudinal axis and around the vertically oriented feed tube 302. Asthe film 310 advances downward, opposing longitudinal side edges 310 a,310 b of the film 310 move between the pair of sealing irons 304 a ofthe longitudinal sealer 304. The machine 300 moves the sealing irons 304a together to seal the side edges 310 a, 310 b of the film 310 togetherto form the side seal portion 108 of the package 100. At this point, theside seal portion 108 of the package 108 extends outward from theremainder of the film 310, as illustrated in FIG. 6. As mentioned, inone embodiment, the longitudinal sealer 304 includes a heat sealer suchthat the sealing irons 304 a of the longitudinal sealer 304simultaneously apply a compressive force and heat energy to the sideedges 310 a, 310 b to form the side seal portion 108. At this stage ofthe forming process, the film 310 takes the shape of a hollow tubedisposed about the bottom end 302 b of the feed tube 302.

Subsequently, the machine 300 advances the hollow tube of film 310between the sealing irons 306 a of the transverse sealer 306. Thesealing irons 306 a of the transverse sealer 306 compress the tube offilm 310 and seal opposing sidewalls together to form the combinationseal 107. As mentioned, in one embodiment, the transverse sealer 306includes a heat sealer such that the sealing irons 306 a of thetransverse sealer 306 simultaneously apply a compressive force and heatenergy to the sidewalls of the tube of film 310 to form the combinationseal 107. As illustrated in FIG. 6, the combination seal 107 includesthe top seal portion 104 of a completely formed, filled, and sealedpackage 100 a and the bottom seal portion 106 of a partially formedintermediate package 100 b.

Accordingly, the intermediate package 100 b includes the side sealportion 108, the bottom seal portion 106, and the folded side edge 110a. The intermediate package 100 b thus defines an open container incommunication with the bottom end 302 b of the feed tube 302. Themachine 300 then delivers a desired amount of product to theintermediate package 100 b. Delivering the product can comprise fillingthe intermediate package 100 b with a flowable substance such as agranulated substance, a fluid, etc. Once the product has been delivered,the machine 300 advances the film 310 such that the combined seal 107 isdisposed between the cutting members 308 a of the cutter 308. Sodisposed, the machine 300 moves at least one of the cutting members 308a toward the other such that the linear cutting blade 308 b cuts thefilm 310 at the combination seal 107, as depicted in FIG. 6, therebydetaching a completely formed, filled, and sealed package 100 c from theremainder of the film 310.

Based on the foregoing, the geometrical configuration of the sealingirons 306 a of the transverse sealer 306 define the profiles of the topand bottom edges 110 c, 110 d of the container portion 102 of thepackage 100. Moreover, the geometrical configuration of the cutter blade308 b of the cutter 308 defines the profiles of the free edges 104 b,106 b of the top and bottom seals 104, 106 of the package 100. Thus, toform the alternative package 200 depicted in FIG. 5, the machine 300 mayhave to be modified.

For example, the cutter 308 would require one or more cutting blades orone or more hot wires having a curved configuration, as depicted in FIG.7. Specifically, FIG. 7 depicts an alternative cutter 408 for use withthe machine 300 for forming packages 200 in accordance with theembodiment of depicted in FIG. 5. Similar to the cutter 308 describedabove with reference to FIG. 6, the cutter 408 includes a pair ofcutting members 408 a, only one of which is depicted. At least one ofthe cutting members 408 a includes a pair of curved cutting blades 410,412, which are depicted in phantom in FIG. 7. Specifically, the cuttingblades 410, 412 are curved away from each other along radiuses that aresimilar or identical to the radiuses of the respective free edges 204 b,206 b of the top and bottom seals 204, 206 of the package 200, as wellas the top and bottom concave edges 307 a, 307 b of the sealing irons306 a of the transverse sealer 306 depicted in FIG. 6. So configured, atleast one of the cutting members 408 a is movable toward the film 310 asit passes therebetween to cut the film 310 and detach a completelyformed, filled, and sealed package 200. Thus, the machine 300 andprocess performed, at least partly by the machine 300, may be adaptedand customized to provide packages of various configuration and designs.

While the product packages 100, 200 of the present invention have thusfar been described as including side seal portions 108, 208 that arelocated adjacent to the second side edges 110 b, 210 b of the respectivepackages 100, 200, alternative embodiments can include side sealportions located elsewhere. For example, FIGS. 8 and 9 depictalternative packages 400, 500 that include side seal portions 415, 515that are located along a mid-portion of respective container portions402, 502 of the packages 400, 500. In one embodiment, the side sealportions 415, 515 can include lap seals, as will be described.

More specifically, FIG. 8 depicts one alternative package 400 thatcomprises a single sheet of film 401 having opposing film portions 402a, 402 b folded along a first side edge 410 a and a second side edge 410b to define the container portion 402. The container portion 402 alsoincludes a top edge 410 c and a bottom edge 410 d. In addition to theside seal portion 415, the package 400 includes a top seal portion 404and a bottom seal portion 406. The side seal portion 415 extends from amid-point A of the top seal portion 404 to a mid-point B of the bottomseal portion 406.

The top seal portion 404 includes a mating edge 404 a and a free edge404 b, and the bottom seal portion 406 includes a mating edge 406 a anda free edge 406 b. In the embodiment depicted in FIG. 8, the top andbottom seal portions 404, 406 are generally identical to the top andbottom seal portions 104, 106 of the package 100 described above withreference to FIGS. 3 and 4. That is, the mating edges 404 a, 406 a ofthe top and bottom seal portions 404, 406 include smooth, curved,concave profiles that mate with smooth, curved, convex profiles of therespective top and bottom edges 410 c, 410 d of the container portion402. Thus, the mating edges 404 a, 406 a intersect with the first andsecond side edges 410 a, 410 b at corners 412 disposed at angles α thatare greater than ninety degrees (90°) and, in one embodiment,approximately one-hundred and thirty-five degrees (135°). Moreover, thefree edges 404 b, 406 b of the top and bottom seal portions 404, 406include linear profiles. Thus, other than the location and construction,which will be described below, of the side seal portion 415, the package400 depicted in FIG. 8 is generally similar to the package 100 depictedin FIGS. 3 and 4.

As mentioned, the embodiment of the side seal portion 415 depicted inFIG. 8 includes a lap seal, and thus, its construction is different fromthe side seal portions 108, 208 of the packages 100, 200 describedabove. For example, as mentioned, the package 400 comprises a singlesheet of film 401. The sheet of film 401 includes opposing first andsecond longitudinal side edges 401 a, 401 b, which combine to form theside seal portion 415. More specifically, the first longitudinal sideedge 401 a of the film 401 overlaps the second longitudinal side edge401 b of the film 401. The overlapping portions of the first and secondlongitudinal side edges 401 a, 401 b are sealed together with heatsealing, ultrasonic sealing, vibrational sealing, or otherwise, asdescribed herein. Thus, the side seal portion 415 constitutes a lap sealthat is disposed within generally the same plane as one of the opposingfilm portions 402 a, 402 b of the completed container portion 402 of thepackage 400. In the embodiment depicted in FIG. 8, the side seal portion415 is disposed in a plane in common with the forward-most film portion402 a.

The manufacturing process for forming the package 400 is slightlydifferent from the manufacturing process described above for thepackages 100, 200. Specifically, the package 400 can be constructedutilizing a vertical form, fill, seal process similar to that which isperformed by the VFFS machine 300 described above with reference to FIG.6, however, the structure and function of various components wouldslightly be changed. As described above, the longitudinal scaler 304 ofFIG. 6 comprises a pair of sealing irons 304 a that compress opposinglongitudinal side edges 310 a, 310 b of the film 310 together to form aside seal portion 108 that extends outward from the remainder of thefilm 310 as it travels along the vertical feed tube 302. The side sealportion 415 of the package 400 depicted in FIG. 8, however, must beformed to be in the same plane as the remainder of the film 401. Thatis, as the film 401 is wrapped around the feed tube 302 depicted in FIG.6, the longitudinal side edges 401 a, 401 b of the film 401 areoverlapped, such that the film 410 forms a complete cylinder, withoutany appendages. Thereafter, the longitudinal sealer 304 would compress,or otherwise, seal the longitudinal edges 401 a, 401 b together. In oneembodiment, the longitudinal sealer 304 can comprise a single scalingiron 304 a adapted to compress the overlapping longitudinal side edges401 a, 401 b of the film 401 together against the feed tube 302.Thereafter, the film 401 continues through the machine 300 to thetransverse sealer 306 and cutter 308. However, because the side sealportion 415 of the completed package 400 depicted in FIG. 8 extends fromthe mid-point A of the top seal 404 to the mid-point B of the bottomseal 406, the transverse sealer 306 and cutter 308 would be positionedninety-degrees (90°) offset from the position depicted in FIG. 6,relative to the longitudinal sealer 304. Nevertheless, the manufacturingprocess proceeds in a manner generally similar to that described aboveto form the top and bottom seal portions 404, 406, and subsequently cuta completed package 400 from the remainder of the film 401. Oneadvantage of utilizing the lap seal 415 extending through a mid-portionof the container portion 402 of the package 400 is that it can decreasethe exposure of the corner 412 to foreign surfaces that may causetearing.

While the top and bottom edges 110 c, 210, 410 c and 110 d, 210 d, 410 dof the container portions 102, 202, 400 of the packages 100, 200, 400and the top and bottom seal portions 104, 204, 404 and 106, 206, 406 ofthe packages 100, 200, 400 have been depicted and described herein asincluding smoothly curved concave or convex profiles, alternativeembodiments of the packages may not include such simple concave orconvex profiles. For example, in alternative embodiments, the concave orconvex profiles may be constructed of two or more linear sectionsarranged end-to-end, for example, to generally define a curved, concave,or convex profile in accordance with the principles of the presentinvention. FIG. 9 depicts one such alternative embodiment that includesa product package 500 having a container portion 502 with convex top andbottom edges 510 c, 510 constructed of a plurality of linear sections.Accordingly, the package 500 also includes top and bottom seal portions504, 506 having concave mating edges 504 a, 506 a constructed ofcomplementary linear sections. Otherwise, the package 500 depicted inFIG. 9 is identical to the package 400 depicted in FIG. 8.

Thus, it should be appreciated that the terms concave and convex, asused herein, are not intended to be limited to simple, smooth curves,but rather, may include variations thereon including, but not limitedto, a plurality of linear sections combined to generally represent aconvex or concave profile. In one alternative embodiment, the profilesmay not include curves at all, but may merely include two linearsections generally defining a V-shaped profile, for example. In anotheralternative embodiment, the convex profiles of the top and bottom edges110 c, 210 c, 410, 510 c and 110 d, 210, 410 d, 510 d of the containerportions 102, 202, 402, 502 of the packages 100, 200, 400, 500 maycomprise a plurality of convex segments arranged to define the overallconvex profile. For example, in such a configuration the convex segmentsmay have a radius of curvature that is smaller than or greater than aradius of curvature of the overall top and bottom edges 110 c, 210 c,410 c, 510 c and 110 d, 210 d, 410 d, 510 d.

Furthermore, while the corners 112, 212, 412, 512 of the containerportions 102, 202, 402, 502 of the packages 100, 200, 400, 500 of thepresent invention have thus far been disclosed as being approximatelyone-hundred and thirty-five degrees (135°), alternative embodiments mayinclude corners 112, 212, 412, 512 of generally any angle and,preferably any angle greater than ninety-degrees (90°). For example, thecorners 112, 212, 412, 512 can be any angle in the range ofapproximately ninety-five degrees (95°) to approximately one-hundred andseventy-five degrees (175°).

Further still, while the longitudinal sealer 304 and the transversesealer 306 have been disclosed herein as comprising sealing irons 304 a,306 a that operate as heat sealers, for example, alternative embodimentsof the sealers 304, 306 may include sealing irons 304 a, 306 a thatoperate as vibrational and/or ultrasonic sealers. In yet otheralternative embodiments, the sealing irons 304 a, 306 a may not provideany energy other than compressive forces, for example, and the side sealportions 108, 415, 515 and combination seals 107 may be created with awater seal, or some other adhesive. Thus, the sealing irons 304 a, 306 aof the present disclosure are not intended to be limited to heat sealingirons, but rather, any type of sealing iron capable of at leastassisting in the creation of the seals.

In light of the foregoing, one advantage of the curved top and bottomedges 110 c, 210, 410 c, 510 c and 110 d, 210 d, 410 d, 510 d of thecontainer portions 102, 202, 402, 502 of the packages 100, 200, 400, 500of the present invention includes the resultant obtuse configuration ofthe corners 112, 212, 412, 512 of the container portions 102, 202, 402,502. Specifically, the obtuse angles of intersection between the top andbottom edges 110 c, 210, 410 c, 510 e and 110 d, 210 d, 410 d, 510 d ofthe container portions 102, 202, 402, 502 and the side edges 110 a, 210a, 410 a, 510 a, and 110 b, 210 b, 410 b, 510 b of the containerportions 102, 202, 402, 502 decreases the stresses otherwise present atthe acute corners 20 of the container portion 12 of the conventionalpackage 10 depicted in FIGS. 1 and 2. This reduction in stress therebyreduces the tendency for the container portions 102, 202, 402, 503 ofthe packages 100, 200, 400, 500 of the present invention to fail.

Another advantage of the curved top and bottom edges 110 c, 210, 410 c,510 c and 110 d, 210 d, 410 d, 510 d of the packages 100, 200, 400, 500of the present invention includes the ability of the packages 100, 200,400, 500 to more closely conform to secondary packaging constraints. Forexample, as mentioned, the primary packages 100, 200, 400, 500 disclosedherein may be offered for distribution or sale in blister-packs.Blister-packs typically include a plurality of blisters having roundedsidewalls. The curved nature of the top and bottom edges 110 c, 210, 410c, 510 c and 110 d, 210 d, 410 d, 510 d of the container portions 102,202, 402, 502 of the packages 100, 200, 400, 500 of the presentinvention may therefore more closely conform to rounded sidewalls,thereby reducing wasted space in the blister and enabling more productto be stored and delivered.

A still further advantage of the packages 100, 200, 400, 500 of thepresent invention includes increased aesthetic appeal and uniquepackaging, which allows consumers to readily identify the contentsand/or the source of the product.

Yet another advantage of the packages 100, 200, 400, 500 of the presentinvention includes the fact that the corners 112, 212, 412, 512 includeangular dimensions a that are greater than ninety degrees such that thecorners 112, 212, 412, 512 are more blunt than the corners 20 of theconventional package 10 depicted in FIGS. 1 and 2. The corners 112, 212,412, 512 of the packages 100, 200 of the present invention therefore donot protrude from the packages 100, 200, 400, 500 as abruptly as thecorners 20 of the conventional package 10, thereby reducing the degreeto which the corners 112, 212, 412, 512 frictionally engage surfacessuch as container walls, for example, which tends to cause tearing andfailure of the conventional packages 10.

It should be appreciated that the foregoing description merely providesexamples and embodiments of the present invention and the presentinvention is not intended to be limited thereby. Rather, the presentinvention is defined by the following claims and intended to includesubject matter falling within the scope and spirit thereof.

1. A product package, comprising: a single sheet of film, the singlesheet of film arranged and configured to comprise: a container portionincluding a side edge, and opposing end edges disposed transverse to theside edge, at least one of the opposing end edges comprising a convexprofile.
 2. The product package of claim 1, wherein the convex end edgecomprising the convex profile intersects the side edge at an angle thatis greater than ninety degrees.
 3. The product package of claim 1,wherein the single sheet of film further comprises opposing end sealportions disposed adjacent to the opposing end edges of the containerportion.
 4. The product package of claim 3, wherein at least one of theopposing end seal portions comprises a concave edge mating with the endedge of the container portion comprising a convex profile.
 5. Theproduct package of claim 3, wherein each of the opposing end edges ofthe container portion comprises a convex profile.
 6. The product packageof claim 5, wherein each of the opposing end seal portions comprises aconcave edge abutting corresponding opposing convex end edges of thecontainer portion.
 7. The product package of claim 6, wherein each ofthe opposing end seal portions further comprises a linear edge spacedfrom the concave edge.
 8. The product package of claim 6, wherein eachof the opposing end seal portions further comprises a convex edge spacedfrom the concave edge.
 9. The product package of claim 1, wherein thesingle sheet of film comprises a water-soluble film.
 10. A product,comprising: a single sheet of film arranged and configured to comprise:a container portion for accommodating a substance, the container portioncomprising first and second end edges, and first and second side edges,each of the first and second end edges comprising a convex profile,first and second end seal portions, the first end seal portioncomprising a concave edge abutting the first end edge of the containerportion, the second end seal portion comprising a concave edge abuttingthe second end edge of the container portion, and at least one of thefirst and second side edges of the container portion comprising a foldededge.
 11. The product of claim 10, wherein the first and second endedges of the container portion intersect at least one of the first andsecond side edges of the container portion at an angle greater thanninety degrees.
 12. The product of claim 10, wherein each of the firstand second end seal portions further comprise a linear edge spaced fromthe concave edge.
 13. The product of claim 10, wherein each of the firstand second end seal portions further comprise a convex edge spaced fromthe concave edge.
 14. The product of claim 10, wherein the single sheetof film comprises a water-soluble film.
 15. A method of forming apackage, comprising: wrapping a single sheet of film about alongitudinal axis of the film; sealing opposing sidewalls of the wrappedfilm together along a first path that is transverse to the longitudinalaxis of the film to form a first end seal portion, the first end sealportion comprising a concave edge; and sealing opposing sidewalls of thewrapped film together along a second path that is transverse to thelongitudinal axis of the film to form a second end seal portion, thesecond end seal portion longitudinally spaced from the first end sealportion, thereby defining a container portion disposed between the firstand second end seal portions, the container portion adapted to contain asubstance.
 16. The method of claim 15, wherein wrapping the single sheetof film comprises at least partly wrapping the single sheet of filmaround a vertical feed tube.
 17. The method of claim 16, furthercomprising sealing opposing longitudinal edges of the wrapped filmtogether to form a tube of film prior to forming the first and secondend seal portions.
 18. The method of claim 17, further comprisingfilling the container portion with a flowable substance prior to formingthe second end seal portion.
 19. The method of claim 15, wherein thesecond end seal portion comprises a concave edge.
 20. The method ofclaim 15, further comprising cutting the film adjacent to the second endseal portion to define a linear edge of the package.
 21. The method ofclaim 15, further comprising cutting the film adjacent to the second endseal portion to define a convex edge of the package.
 22. A productpackage constructed in accordance with the method of claim
 15. 23. Anapparatus for manufacturing a product package from a single sheet offilm, the product package comprising a container portion with at leastone end edge having a convex profile, the apparatus comprising: asealing iron having a first concave edge, the sealing iron adapted toengage the sheet of film such that the first concave edge forms the endedge of the container portion having the convex profile; and a cutterlocated downstream of the sealing iron for cutting the sheet of filmadjacent to the end edge of the container portion having the convexprofile.
 24. The apparatus of claim 23, wherein the cutter comprises acurved cutter to define an edge of the product package having a convexprofile.
 25. The apparatus of claim 24, wherein the curved cuttercomprises a radius equal to a radius of the first concave edge of thesealing iron.